Motor mount assembly for an air cleaner

ABSTRACT

A motor mount assembly for an air cleaner is provided according to an embodiment of the invention. The motor mount assembly includes a motor ring adapted for receiving a motor, a mount ring adapted to be received in the air cleaner, and a plurality of mounting vanes extending between the motor ring and the mount ring. A mounting vane of the plurality of mounting vanes includes a proximal end and a distal end. The distal end is affixed to the motor ring and the proximal end is affixed to the mount ring.

TECHNICAL FIELD

The present invention relates to an air cleaner, and more particularly,to a motor mount assembly for an air cleaner.

BACKGROUND OF THE INVENTION

Air cleaners and purifiers are widely used for removing foreignsubstances from the air. The foreign substances can include pollen,dander, smoke, pollutants, dust, etc. In addition, an air cleaner can beused to circulate room air. An air cleaner can be used in many settings,including at home, in offices, workrooms, etc.

In one prior art air cleaner, a typical air cleaner includes an airmoving device that generates an airflow, such as an electric motor andimpeller. The air moving device is located in an air duct that alsoincludes an air cleaning device(s). As a result, the airflow travelingin the air duct passes through filter elements and/or other air cleaningdevices in order to remove dirt and debris from the airflow.

A typical electrical motor used in an air cleaner comprises acylindrical body including a circumferential surface and two ends. Atypical prior art motor mount can comprise a plate or bracket that isattached to an end of the motor by threaded fasteners. Alternatively, aprior art motor mount can clamp to or be part of the motor itself,including arms that extend radially from the motor, for example.

SUMMARY OF THE INVENTION

A motor mount assembly for an air cleaner is provided according to anembodiment of the invention. The motor mount assembly comprises a motorring adapted for receiving a motor, a mount ring adapted to be receivedin the air cleaner, and a plurality of mounting vanes extending betweenthe motor ring and the mount ring. A mounting vane of the plurality ofmounting vanes comprises a proximal end and a distal end. The distal endis affixed to the motor ring and the proximal end is affixed to themount ring.

A motor mount assembly for an air cleaner is provided according to anembodiment of the invention. The motor mount assembly comprises anairflow shaper including a substantially cylindrical, hollow end and aplurality of cut-outs formed in the end. The motor mount assemblyfurther comprises a motor mount comprising a motor ring adapted forreceiving a motor, a mount ring adapted to be received in the aircleaner, and a plurality of mounting vanes extending between the motorring and the mount ring. A mounting vane of the plurality of mountingvanes comprises a proximal end and a distal end. The distal end isaffixed to the motor ring and the proximal end is affixed to the mountring.

A method of installing a motor in an air cleaner is provided accordingto an embodiment of the invention. The method comprises providing anairflow shaper including a substantially cylindrical, hollow end, aplurality of cut-outs formed in the end, and a plurality of shaperfastener apertures formed in the end. The method further comprisesinserting the motor into the airflow shaper and inserting a plurality offastener bosses of the motor into the plurality of cut-outs of theairflow shaper. The method further comprises sliding a motor mount overthe motor and into contact with the airflow shaper. The motor mountcomprises a motor ring adapted for receiving a motor, a mount ringadapted to be received in the air cleaner, and a plurality of mountingvanes extending between the motor ring and the mount ring. A mountingvane of the plurality of mounting vanes comprises a proximal end and adistal end. The distal end is affixed to the motor ring and the proximalend is affixed to the mount ring. The method further comprises insertinga plurality of motor ring fasteners through a corresponding plurality ofmotor ring fastener apertures of the motor ring and into engagement withthe plurality of shaper fastener apertures of the airflow shaper. Themethod further comprises engaging a plurality of motor fasteners withthe plurality of fastener bosses of the motor. The plurality of motorfasteners clamp one or both of the motor mount and the airflow shaper tothe motor.

BRIEF DESCRIPTION OF THE DRAWINGS

The same reference number represents the same element on all drawings.It should be noted that the drawings are not necessarily to scale.

FIG. 1 shows a tower air cleaner according to an embodiment of theinvention.

FIG. 2 shows at least a portion of a motor mount assembly according toan embodiment of the invention.

FIG. 3 shows a motor in position in the motor ring of the motor mountaccording to an embodiment of the invention.

FIG. 4 shows the motor after addition of an impeller.

FIG. 5 shows the motor and the motor mount from a different angle.

FIG. 6 shows the motor fitted to an airflow shaper according to anembodiment of the invention.

FIGS. 7-8 show the motor and the motor mount fully assembled to theairflow shaper according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-8 and the following descriptions depict specific embodiments toteach those skilled in the art how to make and use the best mode of theinvention. For the purpose of teaching inventive principles, someconventional aspects have been simplified or omitted. Those skilled inthe art will appreciate variations from these embodiments that fallwithin the scope of the invention. Those skilled in the art will alsoappreciate that the features described below can be combined in variousways to form multiple variations of the invention. As a result, theinvention is not limited to the specific embodiments described below,but only by the claims and their equivalents.

FIG. 1 shows a tower air cleaner 100 according to an embodiment of theinvention. The tower air cleaner 100 includes a base portion 101 and atower portion 102. The tower portion 102 can be generally verticallypositioned and elongate in shape. In one embodiment, the tower portion102 can be substantially cylindrical in shape. The tower portion 102includes a shell 103, one or more doors 104, and a control panel 110.The tower portion 102 further includes an air inlet 105 and an airoutlet 106. Air is drawn in through the air inlet 105, is cleaned insidethe tower portion 102, and the cleaned air is exhausted from the airoutlet 106. However, it should be understood that the air cleaner 100can comprise other shapes, configurations, and designs, and the towerconfiguration is shown merely for illustration.

The air inlet 105 is shown as being at the lower end of the towerportion 102. However, it should be understood that alternatively therelative positions of the air inlet 105 and the air outlet 106 could beinterchanged.

FIG. 2 shows at least a portion of a motor mount assembly 200 accordingto an embodiment of the invention. The figure shows a motor mount 202according to an embodiment of the invention. The motor mount 202includes a motor ring 204, a mount ring 205, and a plurality of mountingvanes 208 extending between the motor ring 204 and the mount ring 205.The motor ring 204 holds a motor 230 substantially coaxially centered inthe motor mount 202 (see FIG. 3). The motor ring 204 includes aplurality of fastener clearance troughs 214 and corresponding motor ringfastener apertures 215. The motor ring fastener apertures 215 canreceive motor ring fasteners (not shown) that are used to join the motorring 204 to an airflow shaper 250 (see FIG. 6).

The motor ring 204 further includes a plurality of projecting members211 that extend from an inner surface of the motor ring 204. Theprojecting members 211 can contact the motor 230 and can exert africtional force on the motor 230. The projecting members 211 canadditionally strengthen the motor ring 204.

The mounting vanes 208 extend between the motor ring 204 and the mountring 205 and serve to support the motor 230. A mounting vane 208includes a proximal end 210 and a distal end 209. The distal end 209 isaffixed to the motor ring 204 and the proximal end 210 is affixed to themounting ring 205. It should be understood that the mounting vanes 208can be joined to the motor ring 204 and the mount ring 205, oralternatively the three portions can be formed as an integral unit.

In the embodiment shown, eight mounting vanes 208 are employed. However,the number of mounting vanes 220 can be varied.

The mounting vanes 208 can have an aerodynamic cross-sectional shape.This can include rounded leading edges and can include tapered trailingedges. For example, the mounting vanes 208 can have an airfoilcross-sectional shape. In addition, the mounting vanes 208 can includean arch (better seen in FIG. 3), wherein the mount ring 205 is at alower level than the motor ring 204 when seen from a substantiallyhorizontal position. Furthermore, the mounting vanes 208 can include anangle that conforms to a rotation of the airflow. The rotation can existdue to the rotation of an impeller 233, and angling the mounting vanes208 substantially in alignment with the rotating airflow reduces draggenerated by the mounting vanes 208.

The mount ring 205 is configured to be assembled to a frame or chassis(not shown) of the air cleaner 100. Therefore, the mount ring 205includes a plurality of mount ring fastener apertures 221. In addition,the mount ring 205 includes a plurality of extensions 218 that receiveends of the mounting vanes 208. An extension 218 can include a rib 219.The rib 219 provides additional strength to the extension 218. Inaddition, the rib 219 can fit into a corresponding feature in the frameand can serve an alignment purpose.

FIG. 3 shows a motor 230 in position in the motor ring 204 of the motormount 202 according to an embodiment of the invention. This figureadditionally shows the motor shaft 231. The motor 230 can be snugly orloosely received in the motor ring 204 and can contact the projectingmembers 211. The motor ring 204 can further contact a plurality offastener bosses 234 of the motor 230 (see FIG. 5, for example).

FIG. 4 shows the motor 230 after addition of an impeller 233. Theimpeller 233 generates an airflow that is substantially axially directedwith respect to the motor 230.

FIG. 5 shows the motor 230 and the motor mount 202 from a differentangle. It can be seen from this figure that the motor 230 can includethe plurality of fastener bosses 234. In the embodiment shown, the motor230 includes three fastener bosses 234 equidistantly spaced around acircumference of the motor 202. However, the motor 230 can include anynumber of fastener bosses 234. A fastener boss 234 includes a bore thatreceives a motor fastener. A fastener boss 234 in one embodimentincludes a threaded bore.

FIG. 6 shows the motor 230 fitted to an airflow shaper 250 according toan embodiment of the invention. The airflow shaper 250 in one embodimentcomprises a base 255, a raised central region 256, and an end 251. Theraised central region 256 in one embodiment includes a substantiallycylindrical, hollow end 251. A plurality of shaper fastener apertures253 are formed in the end 251. The shaper fastener apertures 253correspond to the motor ring motor ring fastener apertures 215 of themotor mount 202. Therefore, the motor mount 202 can be affixed to theairflow shaper 250 through use of suitable motor ring fasteners.

The airflow shaper 250 fits over an end of the motor 230 opposite themotor shaft 231. Airflow generated by the motor 230 and impeller 233impinges on the airflow shaper 250 and is redirected by the airflowshaper 250. The fastener bosses 234 of the motor 230 are received incorresponding cut-outs 252 in the airflow shaper 250. Motor fastenerscan engage the fastener bosses 234 and can clamp one or both of themotor mount 202 and the airflow shaper 250 to the motor 230.

FIGS. 7-8 show the motor 230 and the motor mount 202 fully assembled tothe airflow shaper 250 according to an embodiment of the invention.Consequently, the motor ring 204 is abutting the airflow shaper 250. Themotor mount 202 and the airflow shaper 250 in combination can form themotor mount assembly 200. The fastener bosses 234 of the motor 230 arepositioned in the cut-outs 252 of the airflow shaper 250. Correspondingmotor fasteners (not shown) can be installed in the fastener bosses 234,wherein such motor ring fasteners can provide a clamping force onto oneor both of the airflow shaper 250 and the motor ring 204 of the motormount 202. In addition, motor ring fasteners can be installed in thefastener clearance troughs 214 and motor ring motor ring fastenerapertures 215 of the motor ring 204. The motor ring fasteners can engagethe shaper fastener apertures 253 of the airflow shaper 250. As aresult, the motor mount 202 is affixed to the airflow shaper 250.Further, the motor 230 is held with respect to both the motor mount 202and the airflow shaper 250.

The assembled motor 230 and motor mount assembly 200 generates anairflow that is substantially axially directed with respect to the motor230. The resulting airflow impinges on the airflow shaper 250 and isredirected by the airflow shaper 250.

The airflow can pass through one or more filter elements (not shown).The one or more filter elements can remove dirt and debris from theairflow. The one or more filter elements can remove ozone from theairflow, if desired. The one or more filter elements can remove VolatileOrganic Compounds (VOCs) from the airflow, if desired. The one or morefilter elements can remove odors from the airflow, if desired. The oneor more filter elements can treat the airflow to add fragrance or odor,if desired.

The motor mount assembly according the invention can be implementedaccording to any of the embodiments in order to obtain severaladvantages, if desired. The invention provides a motor mount assemblythat provides a substantially rigid and strong mount for a fan motor ofan air cleaner. The invention provides a motor mount assembly thatincludes a plurality of mounting vanes. The invention provides a motormount assembly that comprises substantially aerodynamic mounting vanes.The invention provides a motor mount assembly that comprises mountingvanes that at least partially straighten the airflow. The inventionprovides a motor mount assembly that is easy to install and remove. Theinvention provides a motor mount assembly that presents a minimalresistance to airflow.

1. A motor mount assembly for an air cleaner, comprising: a motor ringadapted for receiving a motor; a mount ring adapted to be received inthe air cleaner; and a plurality of mounting vanes extending between themotor ring and the mount ring, with a mounting vane of the plurality ofmounting vanes comprising a proximal end and a distal end, with thedistal end being affixed to the motor ring and with the proximal endbeing affixed to the mount ring.
 2. The motor mount assembly of claim 1,with the motor ring holding the motor substantially coaxially centeredin the mount ring.
 3. The motor mount assembly of claim 1, wherein amounting vane of the plurality of mounting vanes is angled to besubstantially in alignment with an airflow.
 4. The motor mount assemblyof claim 1, wherein a mounting vane of the plurality of mounting vanesincludes a substantially aerodynamic cross-sectional shape.
 5. The motormount assembly of claim 1, wherein a mounting vane of the plurality ofmounting vanes includes a substantially airfoil cross-sectional shape.6. The motor mount assembly of claim 1, further comprising a pluralityof projecting members disposed inside the motor ring.
 7. The motor mountassembly of claim 1, further comprising an airflow shaper including asubstantially cylindrical, hollow end, wherein the motor fits at leastpartially into the airflow shaper and the motor mount fits over themotor and affixes to the airflow shaper.
 8. The motor mount assembly ofclaim 1, further comprising: a plurality of fastener clearance troughsand corresponding motor ring fastener apertures formed motor ring; andan airflow shaper including a substantially cylindrical, hollow end anda plurality of shaper fastener apertures formed in the end andcorresponding to the plurality of fastener clearance troughs and motorring fastener apertures in the motor ring.
 9. The motor mount assemblyof claim 1, further comprising: an airflow shaper including asubstantially cylindrical, hollow end and a plurality of cut-outs formedin the end; wherein the motor fits at least partially into the airflowshaper, the motor mount fits over the motor, and a plurality ofcorresponding fastener bosses on the motor are received in the pluralityof cut-outs, and further wherein the plurality of fastener bosses areadapted to receive a plurality of motor fasteners that clamp one or bothof the motor mount and the airflow shaper to the motor.
 10. A motormount assembly for an air cleaner, comprising: an airflow shaperincluding a substantially cylindrical, hollow end and a plurality ofcut-outs formed in the end; and a motor mount comprising: a motor ringadapted for receiving a motor; a mount ring adapted to be received inthe air cleaner; and a plurality of mounting vanes extending between themotor ring and the mount ring, with a mounting vane of the plurality ofmounting vanes comprising a proximal end and a distal end, with thedistal end being affixed to the motor ring and with the proximal endbeing affixed to the mount ring.
 11. The motor mount assembly of claim10, with the motor ring holding the motor substantially coaxiallycentered in the mount ring.
 12. The motor mount assembly of claim 10,wherein a mounting vane of the plurality of mounting vanes is angled tobe substantially in alignment with an airflow.
 13. The motor mountassembly of claim 10, wherein a mounting vane of the plurality ofmounting vanes includes a substantially aerodynamic cross-sectionalshape.
 14. The motor mount assembly of claim 10, wherein a mounting vaneof the plurality of mounting vanes includes a substantially airfoilcross-sectional shape.
 15. The motor mount assembly of claim 10, furthercomprising a plurality of projecting members disposed inside the motorring.
 16. The motor mount assembly of claim 10, wherein the motor fitsat least partially into the airflow shaper and the motor mount fits overthe motor and affixes to the airflow shaper.
 17. The motor mountassembly of claim 10, further comprising: a plurality of fastenerclearance troughs and corresponding motor ring fastener apertures formedin the motor ring; and a plurality of shaper fastener apertures formedin the airflow shaper corresponding to the plurality of fastenerclearance troughs and motor ring fastener apertures in the motor ring.18. The motor mount assembly of claim 10, wherein the motor fits atleast partially into the airflow shaper, the motor mount fits over themotor, and a plurality of fastener bosses on the motor are received inthe plurality of cut-outs, and further wherein the plurality of fastenerbosses are adapted to receive a plurality of motor fasteners that clampone or both of the motor mount and the airflow shaper to the motor. 19.A method of installing a motor in an air cleaner, comprising: providingan airflow shaper including a substantially cylindrical, hollow end, aplurality of cut-outs formed in the end, and a plurality of shaperfastener apertures formed in the end; inserting the motor into theairflow shaper and inserting a plurality of fastener bosses of the motorinto the plurality of cut-outs of the airflow shaper; sliding a motormount over the motor and into contact with the airflow shaper, with themotor mount comprising a motor ring adapted for receiving a motor, amount ring adapted to be received in the air cleaner, and a plurality ofmounting vanes extending between the motor ring and the mount ring, witha mounting vane of the plurality of mounting vanes comprising a proximalend and a distal end, with the distal end being affixed to the motorring and with the proximal end being affixed to the mount ring;inserting a plurality of motor ring fasteners through a correspondingplurality of motor ring fastener apertures of the motor ring and intoengagement with the plurality of shaper fastener apertures of theairflow shaper; and engaging a plurality of motor fasteners with theplurality of fastener bosses of the motor, wherein the plurality ofmotor fasteners clamp one or both of the motor mount and the airflowshaper to the motor.
 20. The method of claim 19, with the motor ringholding the motor substantially coaxially centered in the mount ring.21. The method of claim 19, wherein a mounting vane of the plurality ofmounting vanes is angled to be substantially in alignment with anairflow.
 22. The method of claim 19, wherein a mounting vane of theplurality of mounting vanes includes include a substantially aerodynamiccross-sectional shape.
 23. The method of claim 19, wherein a mountingvane of the plurality of mounting vanes includes include a substantiallyairfoil cross-sectional shape.